Method for making window panel units having in situ extruded frames

ABSTRACT

A method of manufacturing a panel unit including a panel and a directly extruded molding. The peripheral edge of a panel is moved along a predetermined orbital path with respect to an extrusion port of a molding die, and a resin molding material is simultaneously extruded directly onto the peripheral edge of the panel. The directly extruded molding has a predetermined external dimension, irrespective of the external dimension of the panel.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of pending application Ser. No.09/229,990 filed Jan. 14, 1999, now U.S. Pat. No. 6,287,406, which is acontinuation of Ser. No. 08/372,320 filed Jan. 13, 1995, now U.S. Pat.No. 6,106,931, which is a continuation of Ser. No. 08/088,520 filed July1, 1993, now U.S. Pat. No. 5,411,696, which is a continuation-in-part ofSer. No. 07/727,945 filed Jul. 10, 1991, now abandoned.

BACKGROUND OF THE INVENTION

The present invention relates to a panel with a frame (which will behereinafter referred to as a panel unit), and also relates to a methodfor manufacturing such a panel unit.

It is known that a frame to be mounted on a peripheral edge of a panelsuch as a window glass for a vehicle is linearly molded by extrudingsynthetic resin, rubber or the like. The linear molding for the frame isthen mounted on the peripheral edge of the panel and bonded thereto witha portion of the frame bent at each corner portion of the panel.

In such a conventional panel unit to be manufactured by employing alinear molding, much time and labor are required in mounting the frameon the peripheral edge of the panel and bonding the frame thereto.Furthermore, there is a possibility of wrinkling and floating of theframe at each corner portion of the panel or in the vicinity thereof.This tends to impair appearance of the panel.

A technique of eliminating the awkward operation in mounting the frameon the peripheral edge of the panel is disclosed in Japanese Laid-openPatent Publication No. 63-15716, for example.

According to this prior art technique, a panel is set within a pair ofinjection molding dies, and the dies are closed. Then, molding materialsuch as resin and rubber is injected into a cavity defined around theperipheral edge of the panel, thereby forming a frame on the peripheraledge of the panel.

However, in the case that the panel is large in size, the cost ofmanufacturing the Injection molding dies becomes high. This willincrease the cost of manufacturing the panel unit.

Furthermore, in closing the injection molding dies, a closing pressureis applied to the panel which tends to damage the panel. Additionally,the molding surface of the dies is marred by the damaged panel,resulting in surface defects of the frame.

A technique for forming the frame on the peripheral edge of the panel isdisclosed in the U.S. Pat. No. 5,057,265 by Kunert et al.

In this prior art technique, a frame is formed along the peripheral edgeof a panel. However, such a technique does not permit formation of aframe which covers a part of the upper and lower surfaces and the endsurface of the panel. Also, such a technique, if there is a variation inthe external dimension of the panel, does not provide a panel unithaving a predetermined external dimension.

SUMMARY OF THE INVENTION

It is, accordingly, an object of the present invention to provide apanel unit which can eliminate the awkward operation in mounting a frameon the peripheral edge of a panel and prevent wrinkling and floating ofthe frame at each corner portion of the panel or in the vicinitythereof.

It is another object of the present invention to provide a panel unithaving a frame which is formed on the peripheral edge of a panel so asto cover a part of the upper and lower surfaces and the end surface ofthe panel, and having a predetermined external dimension.

It is a further object of the present invention to provide a method formanufacturing such a panel unit easily at low costs.

According to a first aspect of the present invention, there is provideda panel unit comprising a window glass panel, and a frame continuouslyformed on a peripheral edge of the window glass by extrusion molding andsimultaneously bonded to the peripheral edge of the window glass panel,the frame being formed on the peripheral edge of the window glass panelso as to cover a part of the upper and lower surfaces and the endsurface of the window glass panel.

The frame is continuously formed on the peripheral edge of the windowglass panel by extrusion molding and is simultaneously bonded thereto.Accordingly, the awkward operation in mounting the frame along theperipheral edge of the window glass panel is eliminated. Further,wrinkling and floating of the frame at each corner portion of the panelor in the vicinity thereof is prevented.

The frame is formed on the peripheral edge of a panel so as to cover apart of the upper and lower surfaces and the end surface of the panel.Accordingly, the frame may effectively protect the peripheral edge ofthe panel. The frame may also cover an adhesive which is used to bondthe frame to the panel, thereby to prevent the adhesive fromdeterioration by ultraviolet light.

According to a second aspect of the present invention, there is provideda method of manufacturing a panel unit including a window glass panel,and a frame mounted on a peripheral edge of the window glass panel. Themethod comprises the steps of providing a window glass panel, preparingmolding die means having an extrusion port for extruding a moldingmaterial, the extrusion port having an inner circumferential surfaceconfigured to a cross section of a frame to be mounted on the peripheraledge of the window glass panel, and an open side surface shaped toexternally receive the peripheral edge of the window glass panel,inserting a part of the peripheral edge of the window glass panel intothe open side surface of the extrusion port to form a molding spacedefined by the peripheral edge of the window glass panel and the innercircumferential surface of the extrusion port, the molding spacecorresponding to the cross section of the frame and having an opening,extruding the molding material from the extrusion port of the moldingdie means into the molding space, and providing continuous movement ofthe window glass panel relative to the molding die means so that theextrusion port of the molding die means is virtually moved around theperipheral edge of the window glass panel, thereby forming the framecovering end surface and a part of the upper and lower surfaces of thewindow glass and extending along the peripheral edge of the windowglass.

The method may permit manufacturing such a panel unit having a framewhich covers a part of the upper and lower surfaces and the end surfaceof a panel at low costs.

Other objects and features of the invention will be more fullyunderstood from the following detailed description and appended claimswhen taken with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational view of the panel unit according to the presentinvention;

FIG. 2 is a sectional view taken along the line II—II in FIG. 1;

FIG. 3 is a schematic perspective view of a vehicle having the panelunit shown in FIG. 1;

FIG. 4 is a perspective view of apparatus for manufacturing the panelunit according to the present invention;

FIG. 5 is an exploded perspective view of the die means shown in FIG. 4;

FIG. 6 is a perspective view of an assembly of the panel retaining meansand the panel moving means shown in FIG. 4;

FIG. 7 is a sectional side view illustrating a driving mechanism for thepanel moving means;

FIG. 8 is an elevational view of FIG. 7;

FIG. 9 is a perspective view of the panel supplying means shown in FIG.4;

FIG. 10 is a sectional side view illustrating a driving mechanism forthe panel supplying means;

FIG. 11 is a perspective view of the panel reserving means shown is FIG.4;

FIGS. 12, 13 and 14 are schematic plan views illustrating the operationwherein the molding is formed by extrusion molding along the peripheraledge of the window glass;

FIG. 15 is an elevational view of the panel unit obtained in theextrusion molding step of the manufacturing method according to thepresent invention;

FIG. 16 is a sectional view of the panel unit in which the panel has adimension identical with a desired value;

FIG. 17 is a sectional view of the panel unit in which the panel has adimension smaller than a desired value;

FIG. 18 is a sectional view of the panel unit in which the panel has ademension than a desired value;

FIG. 19 is a fragmentary sectional view of a panel unit according to asecond embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A panel unit according to a first embodiment of the present inventionwill now be described with reference to FIGS. 1 to 3. In the preferredembodiment, the panel unit is constructed as a front window glass with amolding for a vehicle.

Referring to FIGS. 1 to 3, shown therein and generally designated by thereference number 2 is a panel unit adapted to be fitted in a frontopening of a vehicle body 1. The panel unit 2 is comprised of a windowglass 3 as a panel and a molding 5 as a frame fixed to a peripheral edgeof the window glass 3. The window glass 3 has curved glass surfaces inview of design and aerodynamic characteristics.

As shown in FIG. 2, the molding 5 is bonded to the peripheral edge ofthe window glass 3 by means of resin adhesive 4. Before applying theresin adhesive 4 to the peripheral edge of the window glass 3, theperipheral edge is subjected to primer treatment.

The molding 5 is formed of synthetic resin, rubber or the like. Themolding 5 Is formed by continuously extruding such a molding materialalong the peripheral edge of the window glass 3 and simultaneouslybonding the extruded molding material through the resin adhesive 4 tothe peripheral edge of the window glass 3. By the continuous extrusionmolding, the cross section of the molding 5 is made uniform.

Thus, the molding 5 is continuous along the peripheral edge of thewindow glass 3 and has a uniform cross section.

Furthermore, the molding 5 is automatically fixed to the peripheral edgeof the window glass 3 by extruding molding material along the peripheraledge of the window glass 3 and simultaneously bonding the extrudedmolding material through the resin adhesive 4 to the peripheral edge ofthe window glass 3. Accordingly, it is possible to eliminate theconventional awkward mounting operation wherein a molding independentlyformed is mounted on the peripheral edge of the window glass.Furthermore, it is possible to eliminate wrinkling and floating of themolding at each corner portion of the window glass 3 or in the vicinitythereof, thereby rendering a good appearance to the panel unit.

A preferred embodiment of the manufacturing apparatus according to thepresent invention will now be described with reference to FIGS. 4 to 11.

Referring to FIG. 4, the manufacturing apparatus is generally comprisedof a die means 11 connected to the front end of an extruder 10 forextruding a molding material, a panel retaining means 60 locatedadjacent to the die means 11 for retaining the window glass 3, a panelmoving means 24 connected to the panel retaining means 60 for moving thewindow glass 3 retained by the panel retaining means 60, a panelsupplying means 64 for supplying the window glass 3 to the panelretaining means 60, a panel unit unloading means 95 for unloading thepanel unit 2 from the panel retaining means 60, a panel serving means 96for serving a plurality of window glasses 3 to be removed one by one bythe panel supplying means 64, and a panel unit receiving means 103 forreceiving a plurality of panel units 2 one by one from the panel unitunloading means 95.

Referring to FIG. 5, the die means 11 includes a die body 13 connectedthrough a plurality of fixing bars 12 to the front end of the extruder10. The die body 13 is formed with a molding material supplying passage15 having one end communicating through a joint pipe 14 to a moldingmaterial extruding passage (not shown) formed in the extruder 10 andhaving the other end opening to an outlet 16 recessed on a front endsurface of the die body 13.

A U-shaped guide groove 17 is formed on a side surface of the die body13 so as to engage the peripheral edge of the window glass 3 and guidemovement of the window glass 3. A protection member 18 is bonded to aninner surface of the guide groove 17. The protection member 18 is madeof a rubber material having an elastic compressibility.

A mouthpiece 20 is detachably mounted on the front end surface of thedie body 13 by a plurality of bolts 19. The mouthpiece 20 is formed withan extrusion port 21 communicating with the outlet 16 of the moldingmaterial supplying passage 15. The mouthpiece 20 is further formed witha side opening 22 communicating with the extrusion port 21 for receivingthe peripheral edge of the window glass 3. A protection member 22 a isbonded to upper and lower inner surfaces of the side opening 22. Theprotection member 22 a is formed of a rubber material having an elasticcompressibility. A molding space 23 corresponding to the cross sectionof the molding 5 is defined by the peripheral edge of the window glass 3inserted through the side opening 22 into the extrusion port 21 and byan inner peripheral surface of the extrusion port 21.

Referring to FIGS. 6 to 8, there is shown an assembly of the panelretaining means 60 and the panel moving means 24. The panel moving means24 includes a base 25 fixedly mounted on a floor (not shown). A pair ofrails 27 are provided on the base 25. A slide table 26 is slidablymounted on the rails 27. A screw shaft 29 is rotatably supported on thebase 25. The screw shaft 29 is driven by a motor 28. As best shown inFIG. 7, a nut 30 is provided on a lower surface of the slide table 26 soas to threadedly engage the screw shaft 29. Accordingly, the slide table26 is reciprocatingly moved along the rails 27 by driving the motor 28to forwardly or reversely rotate the screw shaft 29.

A box-like supporting member 31 is mounted on the slide table 26. Anelevating cylinder 32 is supported vertically movably but non-rotatablyon an upper wall of the supporting member 31. A screw shaft 34 isrotatably supported on the elevating cylinder 32 and the slide table 26.The screw shaft 34 is driven by a motor 33 through a gear mechanism 34a. A nut 35 is fixed to a lower opening of the elevating cylinder 32 soas to threadedly engage the screw shaft 34. Accordingly, the elevatingcylinder 32 is vertically moved by driving the motor 33 to forwardly orreversely rotate the screw shaft 34.

A first swivel arm 36 is mounted on an upper end portion of theelevating cylinder 32 so as to be vertically moved together with theelevating cylinder 32 and to be swiveled about the elevating cylinder32. A fixed gear 38 is formed on an outer circumferential surface of theupper end portion of the elevating cylinder 32. A drive gear 40 isprovided in the first swivel arm 36 so as to mesh with the fixed gear 38through an intermediate gear 39. The drive gear 40 is mounted on anoutput shaft 37 a of a motor 37 so as to be rotated together with theoutput shaft 37 a. Accordingly, the first swivel arm 36 is swiveledabout the elevating cylinder 32 by driving the motor 37 to forwardly orreversely rotate the drive gear 40.

A second swivel arm 41 is provided over an upper surface of the firstswivel arm 36 at a fore end portion thereof (i.e., left end portion asviewed in FIG. 7) so as to be swiveled at its base end portion (i.e.,left end portion as viewed in FIG. 8) by a planetary gear mechanism 42.That is, a sun gear 44 rotating together with an output shaft 43 a of amotor 43 and a plurality of planetary gears 45 meshing with the sun gear44 are provided in the fore end portion of the first swivel arm 36. Onthe other hand, an outer ring gear 46 meshing with the planetary gears45 is so formed as to project from a lower surface of the base endportion of the second swivel arm 41. The outer ring gear 46 is guided bya plurality of guide rollers 47 rotatably supported in the fore endportion of the first swivel arm 36. Accordingly, the second swivel arm41 is swiveled about the sun gear 44 by driving the motor 43 to rotatethe sun gear 44 and accordingly rotate the outer ring gear 46 guided bythe guide rollers 47.

As shown in FIG. 8, a rotating member 48 is provided over an uppersurface of the second swivel arm 41 at a fore end portion thereof (i.e.,right end portion as viewed in FIG. 8) so as to be rotated by aplanetary gear mechanism 49. That is, a sun gear 51 rotating togetherwith an output shaft 50 a of a motor 50 and a plurality of planetarygears 52 meshing with the sun gear 51 are provided in the fore endportion of the second swivel arm 41. On the other hand, an outer ringgear 53 meshing with the planetary gears 52 is so formed as to projectfrom a lower surface of the rotating member 48. The outer ring gear 53is guided by a plurality of guide rollers 54 rotatably supported in thefore end portion of the second swivel arm 41. Accordingly, the rotatingmember 48 is rotated about the sun gear 51 by driving the motor 50 torotate the sun gear 51 and accordingly rotate the outer ring gear 53guided by the guide rollers 54.

A tilting member 57 is supported on the rotating member 48 through firstand second shafts 55 and 56 crossing each other so as to be tiltableabout an axis of the first shaft 55 and an axis of the second shaft 56.As shown in FIG. 7, the first shaft 55 is rotatably supported by a pairof bearings (not shown) on opposite side walls of the rotating member48, and one end of the first shaft 55 is directly connected to an outputshaft of a motor 58 mounted on an outer surface of one of the oppositeside walls of the rotating member 48.

As shown in FIG. 8, the second shaft 56 extends through the first shaft55 in orthogonal relationship with each other, and they are fixedtogether. The second shaft 56 is rotatably supported by a pair ofbearings (not shown) on opposite side walls of the tilting member 57,and one end of the second shaft 56 is directly connected to an outputshaft of a motor 59 mounted on an outer surface of one of the oppositeside walls of the tilting member 57.

Accordingly, the tilting member 57 is tilted in a clockwise orcounterclockwise direction as viewed in FIG. 8 by driving the motor 58to forwardly or reversely rotate the first shaft 55. Further, thetilting member 57 is tilted in a clockwise or counterclockwise directionas viewed in FIG. 7 by driving the motor 59 to forwardly or reverselyrotate the second shaft 56.

The panel retaining means 60 is mounted on an upper surface of thetilting member 57. The panel retaining means 60 is generally comprisedof a retaining member 61 having four orthogonal arms 62 fixed to theupper surface of the tilting member 57 and of four suction cups 63 eachmounted on an upper surface of the arm 62 at an outer end thereof. Eachsuction cup 63 is connected to a vacuum source (not shown). Accordingly,under the condition where the window glass 3 is positioned on thesuction cups 63, the window glass 3 is retained by vacuum generated inthe suction cups 63.

Referring to FIGS. 9 and 10, there is shown the panel supplying means 64for supplying the window glass 3 to the panel retaining means 60. Asupporting member 66 is mounted on a base 65 fixed to the floor. Aswivel member 67 is provided over an upper surface of the supportingmember 66 so as to be swiveled by a planetary gear mechanism 68. Thatis, a sun gear 70 rotating together with an output shaft 69 a of a motor69 and a plurality of planetary gears 72 meshing with the sun gear 70are provided in the supporting member 66. On the other hand, an outerring gear 72 meshing with the planetary gears 71 is so formed as toproject from a lower surface of the swivel member 67. The outer ringgear 72 is guided by a plurality of guide rollers 73 rotatably supportedon the supporting member 66. Accordingly, the swivel member 67 isswiveled about the sun gear 70 by driving the motor 69 to rotate the sungear 70 and accordingly rotate the outer ring gear 72 guided by theguide rollers 73.

A first arm 74 is rotatably supported at Its lower end on the swivelmember 67 by a rotating shaft 76 to be driven by a motor 83, and asecond arm 75 is rotatably supported at its lower end on the swivelmember 67 by a rotating shaft 77 to be driven by a motor 84. Further, athird arm 78 is pivotalby supported by a pin 79 at its lower end on anupper end of the second arm 75. A boom 80 is pivotably supported by twopins 81 and 82 on upper ends of the first arm 74 and the second arm 78.Accordingly, the boom 80 is advanced or retracted by driving the motor83 to forwardly or reversely rotate the rotating shaft 76, and is alsotilted about the pin 81 in a clockwise or counterclockwise direction asviewed in FIG. 10 by driving the motor 84 to forwardly or reverselyrotate the rotating shaft 77.

A mounting member 85 is fixed to a fore end of the boom 80. A panelsuction unit 86 for releasably sucking the window glass 3 is suspendedlysupported on the mounting member 85 so as to be tilted about a rotatingshaft 88 to be driven by a motor 89 in a clockwise or counterclockwisedirection as viewed in FIG. 10. The panel suction unit 86 includes aunit body 87 adapted to be tilted by the rotation of the rotating shaft88. A rotating shaft 90 to be driven by a motor 91 projects from a lowersurface of the unit body 87. An arm supporting member 92 is attached toa lower flange of the rotating shaft 90. Four orthogonal arms 93 extendoutwardly from the arm supporting member 92. Four suction cups 94 forsucking the window glass 3 are mounted on lower surfaces of the arms 93at outer ends thereof, respectively. Each suction cup 94 is connected toa vacuum source (not shown).

The panel unit unloading means 95 for unloading the panel unit 2 fromthe panel retaining means 60 is juxtaposed with the panel supplyingmeans 64. The panel unit unloading means 95 has the same construction asthat of the panel supplying means 64. Therefore, the same parts as thoseof the panel supplying means 64 are designated by the same referencenumerals in FIG. 4, and the explanation thereof will be omitted.

Referring to FIG. 11, there is shown the panel serving means 96 adaptedto be movably disposed behind the panel supplying means 64. The panelserving means 96 includes a pallet base 97 movably disposed on thefloor. The pallet base 97 is comprised of a pair of right and left sideframes 98 and a rear frame 99 connecting rear ends of the side frames98, thus forming a U-shaped configuration as viewed in plan.

A pair of right and left supporting frames 100 project from uppersurfaces of the side frames 98 in such a manner as to be inclinedrearwardly.

A plurality of pairs of panel supporting arms 101 are swingablysupported at their base ends on front surfaces of the supporting frames100 by plural pivotal shafts 102. Each panel supporting arm 101 isactuated by an actuating mechanism (not shown) between a horizontalposition in which it supports the window glass 3 and a vertical positionin which it waits for the window glass 3. The window glasses 3 areplaced one by one on the lowermost pair of the panel supporting arms 101to the uppermost pair of the panel reserving arms 101.

The panel unit receiving means 103 for receiving the panel units 2 oneby one from the panel unloading means 95 is juxtaposed with the panelserving means 96. The panel unit receiving means 103 has substantiallythe same construction as that of the panel serving means 96. Therefore,the same parts as those of the panel serving means 96 are designated bythe same reference numerals in FIG. 4, and the explanation thereof willbe omitted.

(Pre-Treatment Step)

The operation of the manufacturing apparatus thus constructed will nowbe described in connection with the manufacturing method of the panelunit.

The peripheral edge of the window glass 3 is preliminarily subjected toprimer treatment, and it is then coated around the periphery with theresin adhesive 4 as shown in FIG. 2. After thus pre-treating a pluralityof the window glasses 3, they are placed one by one on the panelsupporting arms 101 of the panel serving means 96. Then, the panelserving means 96 is moved to a panel supplying position behind the panelsupplying means 64 as shown in FIG. 4.

(Panel Supplying Step)

When the panel serving means 96 is moved to the panel supplyingposition, the panel supplying means 64 is operated. That is, the swivelmember 67 is swiveled by the motor 69 to bring the boom 80 intoorientation to the panel serving means 96. Then, the boom 80 Is advancedand tilted down toward the uppermost window glass 3 in the panelreserving means 96 by driving the motors 83 and 84. At this time, thearm supporting member 92 of the panel suction unit 86 at the fore end ofthe boom 80 is tilted up by driving the motor 89, thereby maintainingthe arms 93 of the arm supporting member 92 in their horizontalposition.

When the suction cups 94 of the panel suction unit 86 are brought intoabutment against an upper surface of the uppermost window glass 3 by theadvancement and the tilt-down of the boom 80, the vacuum sourceconnected to the suction cups 94 is operated to generate a vacuum in thesuction cups 94, thereby holding the window glass 3.

When the window glass 3 is held by the suction cups 94, the boom 80 isretracted and tilted up by driving the motors 83 and 84 with the arms 93of the panel suction unit 86 maintained in the horizontal position, sothat the window glass 3 is lifted from the uppermost pair of the panelsupporting arms 101 in the horizontal position.

Then, the swivel member 67 is swiveled again by driving the motor 69 tobring the boom 80 into orientation to the panel retaining means 60.Then, the boom 80 is advanced and tilted down toward the retainingmember 61 of the panel retaining means 60. At this time, the armsupporting member 92 of the panel suction unit 86 is rotated by themotor 91 so that the peripheral edge of the window glass 3 retained bythe panel suction unit 86 may be brought into a predetermineddirectional relation to the die means 11, that is, the lower portion ofthe peripheral edge of the window glass 3 may be directed to the diemeans 11. Then, the window glass 3 retained by the panel suction unit 86is placed on the suction cups 63 provided on the arms 62 of theretaining member 61 of the panel retaining means 60. The slide table 26of the panel moving means 24 is preliminarily retracted to its leftmostposition as viewed in FIG. 7.

When the window glass 3 is placed on the suction cups 63 of the panelretaining means 60, the vacuum source connected to the suction cups 63is operated to generate a vacuum in the suction cups 63. At the sametime, the vacuum source connected to the suction cups 94 is turned offto restore atmospheric pressure in the suction cups 94. Thus, the windowglass 3 is sucked by the suction cups 63 of the panel retaining means60. On the other hand, the panel supplying means 64 having released thewindow glass 3 is operated to take up the next window glass 3 supportedin the panel serving means 96 and is stopped at its waiting positionshown in FIG. 4.

(Extrusion Molding Step)

In this preferred embodiment, each window glass 3 has curved glasssurfaces as previously mentioned. Accordingly, the window glass 3retained by the panel retaining means 60 is inclined by driving themotor 59 to rotate the second shaft 56 and thereby tilt the tiltingmember 57 and the retaining member 61, so as to bring a central part ofthe lower portion of the peripheral edge of the window glass 3 into ahorizontal position. The peripheral edge is inserted into the sideopening 22 of the mouthpiece 20 of the die means 11 as shown by aphantom line in FIG. 7. Further, the elevating cylinder 32 of the panelmoving means 24 is lifted or lowered by driving the motor 33, so as tomake the height of the central part of the lower portion of the windowglass 3 equal to the height of the side opening 22 of the mouthpiece 20of the die means 11.

Under such an adjusted condition, the slide table 26 is advanced toinsert the central part of the lower portion of the peripheral edge ofthe window glass 3 by a given depth from the side opening 22 into theextrusion port 21 of the mouthpiece 20.

By the insertion of the peripheral edge of the window glass 3 into theextrusion port 21 of the mouthpiece 20, the molding space 23corresponding to the cross section of the molding 5 is defined betweenthe peripheral edge of the window glass 3 and the inner wall surface ofthe extrusion port 21.

Then, a molding material is supplied from the extruder 10 to the moldingmaterial supplying passage 15 in the die means 11, and is extrudedthrough the molding space 23 from the extrusion port 21.

When the molding material is extruded from the extrusion port 21, thefirst and second swivel arms 36 and 41 are swiveled in predetermineddirections, respectively. As a result, the lower portion of theperipheral edge of the window glass 3 is moved relative to the die means11 under the condition where the former is inserted in the extrusionport 21 of the mouthpiece 20. The moving speed of the lower portion ofthe outer periphery of the window glass 3 is set to be substantiallyequal to the extruding speed. Thus, as shown in FIGS. 12 and 13, themolding 5 is continuously formed along the lower portion of theperipheral edge of the window glass 3 from the central part of the lowerportion to a first corner portion 3 a of the window glass 3.

When the first corner portion 3 a of the window glass 3 reaches themouthpiece 20, the rotating member 48 is rotated simultaneously with theswiveling motion of the first and second swivel arms 36 and 41, therebymoving the first corner portion 3 a relative to the die means 11 asshown by a phantom line in FIG. 13. At this time, the tilting member 57is also tilted about the axes of the first and second shafts 55 and 56so as to follow the curvature of the glass surfaces at the first cornerportion 3 a, thereby maintaining the horizontal position of the firstcorner portion 3 a with respect to the mouthpiece 20.

As shown in FIG. 14, when the first corner portion 3 a of the windowglass 3 passes through the mouthpiece 20, and a right portion 3 b of theperipheral edge of the window glass 3 reaches the mouthpiece 20, thetilting member 57 is tilted so as to follow the curvature of the glasssurfaces at the right portion 3 b, thereby maintaining the right portion3 b in its horizontal position with respect to the mouthpiece 20. In thehorizontal position, the right portion 3 b of the peripheral edge of thewindow glass 3 is moved relative to the die means 11 by swiveling thefirst and second swivel arms 36 and 41, thereby continuously forming themolding 5 along the right portion 3 b as shown by a phantom line in FIG.14.

The peripheral edge of the window glass 3 is inserted in the extrusionport 21 of the mouthpiece 20 and is maintained in the horizontalposition by the panel moving means 24 during the formation of themolding 5. The window glass 3 is rotated so that the extrusion port 21is virtually moved along a predetermined orbital path around theperipheral edge of the window glass 3. Furthermore, the window glass 3is rotated at a constant speed substantially equal to the extrudingspeed of the molding material to be extruded from the extrusion port 21.In this manner, the molding 5 is continuously formed along theperipheral edge of the window glass 3. The molding material extrudedfrom the extrusion port 21 is immediately bonded to the peripheral edgeof the window glass 3 coated with the resin adhesive 4 so that themolding 5 is assembled with the window glass 3 to form the panel unit 2.

As shown in FIG. 16, if the longitudinal length of the window glass 3 isL2, which is the ideal longitudinal length m, the molding 5 is formedalong the peripheral edge of the window glass 3 so that the longitudinallength of the panel unit 2 conforms to an ideal length M. As furthershown in FIG. 16, the molding 5 has a longitudinal width W. A distanceH1 is defined between a first peripheral edge of the window glass 3 andthe outer peripheral edge of the molding 5 and a distance H2 is definedbetween a second peripheral edge of the window glass and thecorresponding outer peripheral edge of the molding 5. By moving thewindow glass 3 along a predetermined orbit with respect to the extrusionport 21, the in situ formed molding 5 of the panel unit 2 will alwayshave ideal external dimensions, regardless of variations in the size ofthe window glass 3.

As shown in FIG. 17, even if the longitudinal length of the window glass3 is L1, which is less than the ideal longitudinal length m, the molding5 is formed along the peripheral edge of the window glass 3 so that thelongitudinal length of the panel unit 2 still conforms to the ideallength M. FIG. 17 shows that the length U of the window glass 3 is lessthan the ideal length m by the amount A (i.e., distances H1 and H2 ofFIG. 17 are greater than distances H1 and H2 of FIG. 16) and the in situmolding 5 formed by moving the window glass 3 in a predetermined orbitalpath compensates for the difference A/2 at each side of the window glass3 to provide a panel unit 2 having the ideal external dimensions.

Further, as shown in FIG. 18, even if the longitudinal length of thewindow glass 3 is L3, which is greater than the ideal longitudinallength m, the molding 5 is formed along the peripheral edge of thewindow glass 3 so that the longitudinal length of the panel unit 2 stillconforms to the ideal constant length M. FIG. 18 shows that the lengthL3 of the window glass 3 is greater than the ideal length m by theamount B (i.e., distances H1 and R2 of FIG. 18 are less than distancesH1 and H2 of FIG. 16) and the in situ molding 5 formed by moving thewindow glass 3 in a predetermined orbital path compensates for thedifference B/2 at each side of the window glass 3 to provide a panelunit 2 having the ideal external dimensions.

As described above, even if there is a variation in the externaldimension of the window glass 3, the molding 5 effectively compensatesfor the variation without departing from the ideal external dimension ofthe in situ formed molding 5, thereby permitting the consistentformation of panel units 2 having uniform external dimensions.

This results from the fact that the molding 5 is formed on theperipheral edge of the window glass 3 so as to cover a part of the upperand lower surfaces and the end surface of the window glass 5.

In the foregoing description, the tilting member 57 is controlled sothat the peripheral edge of the window glass 3 maintains a desired anglewith respect to the mouth piece 20. It is to be understood, however,that the invention is not to be limited to the description. Therefore,the tilting member 57 can be controlled so that the peripheral edge ofthe window glass 3 maintains a desired angle with respect to the mouthpiece 20.

(Panel Unit Unloading Step)

When the molding 5 is formed along almost the entire peripheral edge ofthe window glass 3, the supply of the molding material is stopped.

After the panel unit 2 is obtained in the above-mentioned extrusionmolding step, the slide table 26 of the panel moving means 24 isretracted to the original position, so as to remove the peripheral edgeof the window glass 3 from the extrusion port 21 through the sideopening 22 of the mouthpiece 20. Thereafter, the panel unit 2 is removedby the panel unit unloading means 95, and is placed on a lowermost pairof panel unit receiving arms 101 of the panel unit receiving means 103.

Similarly to the above operation, the remaining window glasses 3 placedon the remaining pairs of the panel supporting arms 101 of the panelserving means 96 in the pre-treatment step are supplied one by one tothe panel retaining means 60 by the panel supplying step, and are thenformed into the panel units 2 by the die means 11 in the extrusionmolding step. Thereafter, the panel units 2 are removed one by one bythe panel unit unloading means 95 to be received by the panel unitreceiving arms 101 of the panel unit receiving means 103 in the panelunloading step. Finally, when the panel unit 2 is placed on theuppermost pair of the panel unit receiving arms 101 of the panel unitreceiving means 103, the panel unit receiving means 103 including thepanel units 2 is moved to a predetermined position.

(Post-Treatment Step)

In the case that the shape of the molding 5 becomes irregular just afterstarting of the extrusion molding and just before ending of theextrusion molding, a part of the molding 5 having such an irregularshape is eliminated as waste pieces 6 as shown in FIG. 15.

In general, the lower portion of the peripheral edge of the front windowglass 3 for a vehicle is not provided with the molding 5. Accordingly, apart of the molding 5 formed along the lower portion of the peripheraledge of the window glass 3 can be eliminated as the waste pieces 6.

In the case that the panel is a rear window glass for a vehicle, it isnecessary to mount a molding along the entire peripheral edge of therear window glass. In this case, an additional molding piece (not shown)having a length L equal to the sum of lengths of the waste pieces 6 andthe central part of the lower portion of the peripheral edge of thewindow glass as shown in FIG. 15 is formed independently of the molding5. The additional molding piece is mounted on the lower portion of theperipheral edge of the window glass after forming the molding 5.

Although the above preferred embodiment employs the window glass 3 for avehicle as the panel and the molding 5 as the frame, the panel and theframe in the present invention are not limited to the above. Forinstance, the panel may be a resin or metal panel.

Further, although the window glass 3 retained by the panel retainingmeans 60 is moved relative to the fixed die means 11 by the panel movingmeans 24 in the above preferred embodiment, the die means 11 may beconnected to any moving means (not shown), and the panel retaining means60 may be fixed, so that the die means 11 can be moved relative to thewindow glass 3 retained by the panel retaining means 60.

A panel unit according to a second embodiment of the present inventionwill now be described with reference to FIG. 19, wherein since methodand apparatus for manufacturing the panel unit are the same as those formanufacturing the panel unit according to the first embodiment of thepresent invention, the explanation thereof will be omitted.

As shown in FIG. 19, the panel unit is generally designated by thereference number 202 and is comprised of a window glass 203 and amolding 205 fixed to a peripheral edge of the window glass 203. Themolding 205 is immediately bonded to the peripheral edge of the windowglass 203 by means of resin adhesive 204. The molding 205 includes aportion 205 a contacting the outer surface 203 a of the window glass203. As shown therein, the thickness of the portion 205 a is extremelyreduced for flowing air smoothly over the molding 205, thereby toenhance the aerodynamic performance of an automobile on which the panelunit 202 is mounted. In this embodiment, the thickness of the portion205 a is 1.5 mm or less.

While the invention has been described with reference to a specificembodiment, the description is illustrative and is not to be construedas limiting the scope of the invention. Various modifications andchanges may occur to those skilled in the art without departing from thespirit and scope of the invention as defined by the appended claims.

What is claimed is:
 1. A method of manufacturing a panel unit comprisinga panel and a directly extruded molding, comprising: moving either oneof the panel and a molding die with respect to the other of the paneland the molding die so that a peripheral edge of the panel moves along apredetermined orbital path with respect to an extrusion port of themolding die; simultaneously extruding a resin molding material directlyonto the peripheral edge of the panel, stopping the extrusion of theresin molding material when the directly extruded molding is formedalong almost the entire peripheral edge of the panel, and eliminating anirregular portion of the directly extruded molding, wherein the directlyextruded molding has a predetermined external dimension, irrespective ofthe external dimension of the panel, and a gap is formed between a firstand a second terminal end of the directly extruded molding.
 2. A methodas in claim 1, comprising continuously moving the extrusion portrelative to the panel and simultaneously bonding the resin moldingmaterial to the peripheral edge of the panel.
 3. A method as in claim 1,further comprising connecting the first and second terminal ends of thedirectly extruded molding filling the gap with an additional molding. 4.A method as in claim 1, further comprising mounting an additionalmolding piece in the gap, wherein the directly extruded molding and theadditional molding piece form a continuous molding around the entireperipheral edge and four corners of the panel.
 5. A method as in claim1, wherein the panel is an automobile window glass.
 6. A method as inclaim 5, comprising continuously moving the panel relative to theextrusion port and simultaneously bonding the resin molding material tothe peripheral edge of the panel.
 7. A method as in claim 6, furthercomprising connecting the first and second terminal ends of the directlyextruded molding with an additional molding, wherein the directlyextruded molding and the additional molding form a continuous moldingaround the entire peripheral edge and four corners of the automobilewindow glass.
 8. A method as in claim 1, wherein the peripheral edge ofthe panel is disposed proximally to the extrusion port during theextrusion molding step.
 9. A method as in claim 8, wherein theperipheral edge of the panel is inserted into the extrusion port duringthe extrusion molding step.
 10. A method as in claim 9, wherein thepanel is an automobile window glass.
 11. A method as in claim 10,further comprising mounting an additional molding piece in the gap,wherein the directly extruded molding and additional molding piecetogether extend around the entire peripheral edge and four corners ofthe automobile window glass.
 12. A method as in claim 1, wherein theextrusion port is fixed in position and the panel is rotated, such thatthe peripheral edge of the panel follows the predetermined orbital path.13. A method as in claim 12, wherein the peripheral edge of the panel isdisposed proximally to the extrusion port during the extrusion moldingstep.
 14. A method as in claim 13, wherein the peripheral edge of thecurved panel is inserted into the extrusion port during the extrusionmolding step.
 15. A method of manufacturing a panel unit comprising apanel and a directly extruded molding having a predetermined ideal outerdimension, even if the external dimension of the panel varies from anideal external dimension, comprising: extruding a molding material froma molding die directly onto a peripheral edge of the panel by movingeither one of the panel and the molding die with respect to the other ofthe panel and the molding die so that the peripheral edge of the panelmoves along a predetermined path with respect to the molding die,wherein the predetermined path defines the ideal outer dimension of thedirectly extruded molding, stopping the extrusion of the resin moldingmaterial when the directly extruded molding is formed along almost theentire peripheral edge of the panel, and eliminating an irregularportion of the directly extruded molding, wherein the directly extrudedmolding has the ideal outer dimension, irrespective of the externaldimension of the panel, and a gap is formed between a first and a secondterminal end of the directly extruded molding.
 16. A method as in claim15, comprising continuously moving the molding die relative to the paneland simultaneously bonding the molding material to the peripheral edgeof the panel.
 17. A method as in claim 16, wherein the panel is anautomobile window glass.
 18. A method as in claim 17, further comprisingconnecting the first and second terminal ends of the directly extrudedmolding with an additional molding.
 19. A method as in claim 15, furthercomprising mounting an additional molding piece in the gap, wherein thedirectly extruded molding and the additional molding piece form acontinuous molding around the entire peripheral edge and four corners ofthe panel.
 20. A method as in claim 15, wherein the peripheral edge ofthe panel is disposed proximally to the molding die during the extrusionmolding step.
 21. A method as in claim 20, wherein the peripheral edgeof the panel is inserted into the molding die during the extrusionmolding step.
 22. A method as in claim 21, wherein the panel is anautomobile window glass.
 23. A method as in claim 22, comprisingcontinuously moving the peripheral edge of the automobile window glassrelative to the molding die and simultaneously bonding the moldingmaterial to the peripheral edge of the automobile window glass.
 24. Amethod as in claim 23, further comprising mounting an additional moldingpiece in the gap, wherein the directly extruded molding and additionalmolding piece together extend around the entire peripheral edge and fourcorners of the automobile window glass.
 25. A method as in claim 15,wherein the extrusion port is fixed in position and the panel isrotated, such that the peripheral edge of the panel follows thepredetermined orbital path.
 26. A method as in claim 25, wherein theperipheral edge of the panel is disposed proximally to the molding dieduring the extrusion molding step.
 27. A method as in claim 26, whereinthe peripheral edge of the panel is inserted into the molding die duringthe extrusion molding step.
 28. A method of manufacturing a panel unitincluding a window glass panel, and a frame mounted on a peripheral edgeof the window glass panel, comprising: providing a molding die having anextrusion port for extruding a molding material to form the frame,wherein the extrusion port has an inner circumferential surface thatcorresponds the cross section of the frame, disposing the peripheraledge of the window glass panel proximally with respect to the extrusionport in order to form a molding space defined by the peripheral edge ofthe window glass panel and the inner circumferential surface of theextrusion port, wherein the molding space corresponds to the crosssection of the frame; extruding the molding material into the moldingspace; continuously moving either one of the window class panel and themolding die with respect to the other of the window glass panel and themolding die so that the peripheral edge of said window glass panel movesalong a predetermined orbital path with respect to the extrusion port ofthe molding die, thereby forming a directly extruded molding, stoppingthe extrusion of the resin molding material when the directly extrudedmolding is formed along almost the entire peripheral edge of the panel,and eliminating an irregular portion of the directly extruded molding,thereby forming the panel unit having a predetermined external dimensionwherein a gap is formed between a first and a second terminal end of thedirectly extruded molding.